Enhanced sinter efficiency by optimised quality control (Sinter efficiency) : final report

A PGNAA test device was developed and installed to measure the sinter raw mixture composition in situ at TKSE. Based on the results of the measurement a limestone dosing control (LDSC) was implemented into the sinter process control. PGNAA and LSDC are working very well and the basicity level is much more homogeneous. The evaluation of long-term trials has shown that a great benefit of EUR 0.11/tsinter can be expected by using the new devices. A XRF in situ measurement and a basicity controller were implemented into the control system at the VASD sinter plant. Very good results were achieved. Since September 2009 the basicity controller based on the XRF measurement system has been more or less in continuous operation. The result of the control interventions is a much more uniform basicity of the sinter. BFI and TKSE investigated the on-strand (cold) permeability. A device for continuous measurement of the on-strand permeability was enhanced with respect to accuracy and long-time stability. Sinter mix moisture, bulk density and BTP fluctuations were investigated by operational trials with different sinter mix compositions. A software tool was developed and implemented to optimise the permeability by automatic detection of the optimum moisture. Corus demonstrated the contribution of cold permeability to the post-ignition gas flow rate (hot permeability). Mechanisms by which hot permeability and/or flame front affect sinter productivity were also studied through sinter pot tests. In addition, a method to monitor the on-line bed permeability has been developed at strand No 2 of the IJmuiden sinter plant.